Ground-Based Battery Coolant Conditioning for Fast-Charge Aircraft

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Solution Overview

Problem

Electric aircraft face challenges with poor energy storage and recharging capabilities, and the thermal management of batteries is critical for optimal performance, as excessive heat hinders fast charging.

Innovation Solution

A ground-based thermal conditioning system that fluidically connects an onboard thermal conditioning module with a ground-based module, using a liquid coolant to regulate the temperature of the electric aircraft's power supply during charging, thereby preventing overheating and enabling safe and efficient fast recharging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If fast charging is implemented for electric aircraft batteries, then recharging capability is improved, but thermal management becomes more difficult and overheating risk increases

Engineering Contradiction:

Improverecharging capabilityVSAvoidbattery temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The system performs preliminary thermal conditioning of batteries before fast charging begins. The ground-based thermal conditioning module pre-cools or pre-heats batteries to optimal temperature ranges, ensuring they are thermally prepared to receive high-rate charging without immediate overheating risks.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces an intermediary thermal conditioning system between the battery and charging process. This includes ground-based thermal conditioning modules with coolant circulation systems that act as a mediator to manage heat transfer, allowing fast charging to proceed while maintaining safe operating temperatures through controlled thermal exchange.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If thermal conditioning systems are added to manage battery temperature, then battery performance is improved, but system complexity increases

Engineering Contradiction:

Improvebattery performanceVSAvoidthermal conditioning system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The thermal conditioning system is segmented into separate functional modules: onboard thermal conditioning units integrated with the aircraft, ground-based thermal conditioning modules at charging stations, and coolant circulation systems. This segmentation allows each component to be optimized independently and simplifies maintenance and operation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The thermal conditioning system is designed to perform multiple functions: cooling batteries during fast charging, heating batteries in cold environments, and providing thermal management during storage. The ground-based module can serve multiple aircraft simultaneously, reducing overall system complexity through shared infrastructure.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If ground-based thermal conditioning is implemented, then safe fast recharging is enabled, but infrastructure requirements increase

Engineering Contradiction:

Improvefast rechargingVSAvoidground-based infrastructure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system merges the thermal conditioning function with existing ground-based charging infrastructure. The ground-based thermal conditioning module is integrated into the charging station, combining power delivery and thermal management in a single unified system rather than requiring separate independent systems.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The thermal conditioning system is designed to operate autonomously with automatic temperature sensing and coolant flow control. The system self-regulates thermal conditions based on battery state, reducing the need for complex manual control infrastructure and simplifying ground-based requirements.

Inventive Principle:

Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system effectively manages the thermal conditions of electric aircraft batteries, ensuring optimal performance and safe, efficient charging by cooling critical components, thus overcoming the limitations of existing charging methods.

Implementation Method 1

pumping a liquid coolant through a thermal conditioning channel of the ground-based thermal conditioning module to a thermal conditioning channel of the onboard thermal conditioning module

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

pumping a liquid coolant through a thermal conditioning channel

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS11801773B1Methods and systems for ground-based thermal conditioning for an electric aircraft

Publication Date: 2023.10.31 BETA AIR LLC

AI summary

A method and system for ground-based thermal conditioning of an electric aircraft. The system includes an electric aircraft, an onboard thermal conditioning module on the electric aircraft, and a ground-based thermal conditioning module connected to the onboard thermal conditioning module. Liquid coolant runs through the ground-based thermal conditioning module to the onboard thermal conditioning module. Ground-based thermal conditioning module purges the coolant from the onboard thermal conditioning module. The ground-based thermal conditioning module is disconnected from the onboard thermal conditioning module.